A method for forming an assembly having a housing and first and second components. The first and second components are movable relative to one another in the housing. The method includes: providing first and second workpieces; moving the first and second workpieces relative to one another in a predetermined manner that produces relative sliding contact between the first and second workpieces while performing a superfinishing operation on the first and second workpieces to form the first and second components, respectively, wherein the superfinishing operation does not comprise a lapping operation; and mounting the first and second components in the housing such that the first and second components are engaged to one another and are movable relative to one another in the predetermined manner.

A vehicle differential device includes a plurality of pinion gear sets. Each of the pinion gear sets includes a first pinion gear configured to mesh with a first outer helical gear and a plurality of second pinion gears configured to mesh with a second outer helical gear. The first pinion gear integrally includes an axially one end side gear portion configured to mesh with the first outer helical gear and an axially other end side gear portion configured to mesh with the second pinion gears. The second pinion gears are configured to mesh with the second outer helical gear at positions separated from each other in a circumferential direction of the second outer helical gear, and the axially other end side gear portion of the first pinion gear is configured to mesh with the second pinion gears at positions radially outward of the second outer helical gear.

A differential device includes a ring gear receiving a rotational driving force from a drive gear, a differential case rotating integrally with the ring gear around a predetermined axis, and a differential mechanism installed within a barrel part of the differential case. The ring gear includes a gear portion meshing with the drive gear, and a rim portion that is formed integrally with an inner periphery of the gear portion and is fitted, in a non-welded state, onto a maximum diameter outer peripheral portion of the barrel part or a predetermined outer peripheral portion having a smaller diameter than the maximum diameter outer peripheral portion. The rim portion has a to-be-fixed portion welded to the barrel part at a position spaced in an axial direction from a fitting part via which the rim portion and the barrel part are fitted, the position being further radially inward than the fitting part.

A differential carrier and ring gear assembly for a vehicle is provided. The assembly comprises a differential carrier, a ring gear, and a weld nugget. The differential carrier comprises an outer surface including a first contact face having a weld end extending to a root end. The first contact face has a first slot formed on a first radial portion thereof. The ring gear is disposed about the differential carrier and comprises an inner side having an inner surface. The inner side has a stop flange abutting the root end. The inner surface comprises a second contact face disposed on the first contact face such that the root end is in abutment with the second end. The first and second hollow channels define a pocket therebetween and the first slot defines a first vent hole for venting. The weld nugget is disposed between the first and second contact faces.

A vehicle drivetrain assembly (10) and method for making the assembly of first and second torque transmitting members (12, 14), one of which (12) is aluminum and the other of which (14) is steel, that are joined by an electromagnetic pulse weld (16) progressively applied along a radial direction relative to the axis (A) of assembly rotation so as to provide a lightweight construction.

A method for forming an assembly having a housing and first and second components. The first and second components are movable relative to one another in the housing. The method includes: providing first and second workpieces; moving the first and second workpieces relative to one another in a predetermined manner that produces relative sliding contact between the first and second workpieces while performing a superfinishing operation on the first and second workpieces to form the first and second components, respectively, wherein the superfinishing operation does not comprise a lapping operation; and mounting the first and second components in the housing such that the first and second components are engaged to one another and are movable relative to one another in the predetermined manner.

An output ring gear for use in an integrated drive generator has a gear body extending between a first end and a second end and having a disc extending radially outwardly. A boss extends from the disc toward the second end. There are outer gear teeth outwardly of an outer diameter of the disc. There are inner gear teeth inwardly of an inner surface of the disc. The outer and inner gear teeth have a unique gear tooth profile with roll angles A, B, C, and D. An integrated drive generator and a method are also disclosed.

In a differential device including a differential case having a case main body with an access window, a flange part includes: a first flange part outside a region sandwiched by paired imaginary straight lines passing through an axis and inner ends, on one and another sides in a peripheral direction of the case, of the window when viewed on a projection plane orthogonal to the axis; and the second flange part in the region. The second flange part includes a predetermined region spaced in the peripheral direction from a border part with the first flange part and capable of avoiding stress concentration around a degassing passage in the predetermined region when a thrust load acts on the flange part so as to generate stress resisting inclination thereof. The degassing passage is disposed only in the first flange part, only in the predetermined region, or only in both of them.

A drive module having a housing, an input pinion, a ring gear driven by the input pinion, a ring gear bearing supporting the ring gear for rotation relative to the housing, a pair of output shafts and a clutch that selectively transmits rotary power between the ring gear and the output shafts. The clutch includes a clutch input, which is rotatably coupled to the ring gear, a clutch plate separator that is rotatably coupled to the clutch input, a pair of clutch outputs, which are each coupled to a respective one of the output shafts, a pair of clutch packs, which transmit rotary power between the clutch input and a respective one of the clutch outputs, and a pair of apply pistons. The apply pistons are housed in the clutch plate separator.

A vehicle driveline component having a limited slip differential with a differential gearset and a pair of clutch packs received in a differential case. The differential gearset employs side gears that are meshed with first differential pinions, which are mounted about a first pin axis, and second differential pinions, which are mounted about a second pin axis that is not perpendicular to the first pin axis. The teeth of the first differential pinions are formed with drive side having a first pressure angle. The teeth of the second differential pinions are formed with a coast side having a second pressure angle that is different from the first pressure angle. The teeth of the side gears are asymmetric and have a first side, which is formed with the first pressure angle, and a second side that is formed with the second pressure angle.